Blade outer air seal having partial coating

ABSTRACT

A blade outer air seal member includes a body that extends between two circumferential sides, axially between a leading edge and a trailing edge, and between a gas path side and a radially outer side opposite the gas path side. A ceramic coating is initially disposed on a portion of the gas path side outside of a blade rub area of the gas path side such that the blade rub area is bare with regard to any ceramic coating.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

This invention was made with government support under contract numbersF33615-95-C-2503 and F33615-97-C-2779 awarded by the United States AirForce. The government has certain rights in the invention.

BACKGROUND

This disclosure relates to seals and, more particularly, to a bladeouter air seal member for a gas turbine engine.

Conventional gas turbine engines are widely known and used asground-based turbines for energy production or for propelling aircraftor other vehicles. Typically, a gas turbine engine includes a compressorsection, a combustor section, and a turbine section that cooperate inthe combustion of fuel to expand combustion gases over the turbinesection in a known manner.

A blade outer air seal is located radially outwards from the turbinesection and functions as an outer wall for the hot gas flow through theturbine section. Due to large pressures and the contact with the hot gasflow, the blade outer air seal is made of a strong, oxidation-resistantmetal alloy and requires a cooling system to keep the alloy below acertain temperature. For example, relatively cool air is taken from anair flow through the engine (e.g., compressor) and routed through anintricate system of cooling passages in the seal to maintain a desirableseal temperature. The gas path surface of the blade outer air seal mayinclude a thermal, environmental or corrosion resistance coating systemto help protect the underlying metal alloy.

SUMMARY

Disclosed is a blade outer air seal member that includes a body thatextends between two circumferential sides, axially between a leadingedge and a trailing edge, and between a gas path side and a radiallyouter side opposite the gas path side. A ceramic coating is initiallydisposed on a portion of the gas path side outside of a blade rub areaof the gas path side such that the blade rub area is bare with regard toany ceramic coating.

In another aspect, the blade outer air seal member also includes acooling passage that has an outlet hole that opens at the bare area. Thecooling passage extends in the body in an axial direction such that aportion of the cooling passage is adjacent the ceramic coating.

Also disclosed is a method for enhancing durability of a blade outer airseal member. The method includes establishing a greater amount ofcooling to the blade rub area of the gas path side than to the portionthat is coated.

The various features and advantages of the disclosed examples willbecome apparent to those skilled in the art from the following detaileddescription. The drawings that accompany the detailed description can bebriefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates an example turbine section.

FIG. 2 illustrates an example blade outer air seal member having apartial ceramic coating.

FIG. 3 illustrates another example blade outer air seal member having apartial ceramic coating and a cooling passage that extends under thecoating.

FIG. 4 illustrates another example blade outer air seal member that hasa tapered ceramic coating.

FIG. 5 illustrates an example blade outer air seal member that has a rowof circumferential cooling holes.

FIG. 6 is a cross-sectional view of the blade outer air seal member ofFIG. 5.

DETAILED DESCRIPTION

FIG. 1 illustrates a selected portion of a turbine section 20 of a gasturbine engine. The gas turbine engine is of known arrangement andincludes a compressor section, a combustion section and the turbinesection 20. The turbine section 20 includes turbine blades 22 andturbine vanes 24.

The turbine blades 22 receive a hot gas flow 26 from the combustionsection of the engine. The turbine section 20 includes a blade outer airseal system 28 having a blade outer air seal member 32 that functions asan outer wall for the hot gas flow 26 through the turbine section 20. Inthe disclosed example, the blade outer air seal member 32 is removablysecured to a support 34 using L-shaped hooks or other attachmentfeatures. The support 34 is secured to a case 36 that generallysurrounds the turbine section 20. The turbine section 20 is providedwith a plurality of blade outer air seal members 32, or segments, thatare circumferentially arranged about the turbine blades 22. The featuresof the blade outer air seal member 32 that will be described below withregard to the normal orientation of the blade outer air seal member 32in the engine relative to a central axis A of the engine.

FIG. 1 is a schematic presentation to illustrate an example operatingenvironment of the blade outer air seal member 32 and is not alimitation on the disclosed examples. Additionally, there are varioustypes of gas turbine engines, many of which could benefit from theexamples disclosed herein.

FIG. 2 illustrates an example of the blade outer air seal member 32. Inthe illustration, the blade outer air seal member 32 is shown in asimplified view, without connection features or cooling passages thatmay be included. In this example, the blade outer air seal member 32includes a body 40 that extends between two circumferential sides 42(one shown), axially between a leading edge 44 a and a trailing edge 44b, between a gas path side 46 a and a radially outer side 46 b oppositethe gas path side 46 a.

A coating 48 is initially disposed on a portion 50 of the gas path side46 a. The portion 50 is outside of a blade rub area 52 (i.e., surface)of the gas path side 46 a. The blade rub area 52 is initially bare withregard to any of the coating 48. The blade rub area 52 optionallyincludes another type of types of non-ceramic or non-thermal barriercoatings (e.g., MCrAlY), but does not include a ceramic coating. Thatis, the blade rub area 52 is bare with, regard to any ceramic coating,prior to any contact with the tips of the blades 22 and is not bare fromabrasion contact with the blades 22. For example, the blade rub area 52is directly outboard of the tips of the blades 22 and rubs against thetips during a wear-in period of the blade outer air seal member 32.After the wear-in period, there is reduced or no contact between thetips and the blade rub area 52.

In the illustrated example, the coated portion 50 of the gas path side46 a includes a first area (to the left of the blade rub area 53 in theillustration) that extends along the leading edge 44 a and a second area(to the right of the blade rub area 53 in the illustration) that extendsalong the trailing edge 44 b. The blade rub area 52 separates the firstarea from the second area, although in other examples the portion 50need not be divided. In a further example, the blade rub area 52 bisectsthe coated portion 50 such that the size of the first area isapproximately equivalent to the size of the second area. It is to beunderstood that in other examples, the sizes of the first area and thesecond area need not be equal and the sizes may depend upon theparticular design of the turbine section 20.

FIG. 3 illustrates another example blade outer air seal member 132. Inthis disclosure, like reference numerals designate like elements whereappropriate and reference numerals with the addition of one-hundred ormultiples thereof designate modified elements. The modified elements areunderstood to incorporate the same features and benefits of thecorresponding elements. In this example, the blade outer air seal member132 is similar to the blade outer air seal member 32 shown in FIG. 2,but additionally includes a cooling passage 60 that extends within thebody 40. The blade outer air seal member 132 may include multiple ofsuch cooling passages 60. The cooling passage 60 has an outlet hole 62that opens at the blade rub area 52. The cooling passage 60 extends inthe body 40 in an axial direction relative to engine axis A such that aportion 64 of the cooling passage 60 is adjacent to the coating 48. In afurther example, the portion 64 of the cooling passage 60 is axiallyaligned (i.e., at the same axial position), as represented at 66, with apart of the coating 48. That is, the cooling passage 60 in this exampleextends forward from the outlet hole 62 toward the leading edge 44 a andunderneath a portion of the coating 48. In this example, the coolingpassage 60 has an inlet hole 68 on the radially outer side 46 b of theblade outer air seal member 132.

In operation, the tips of the blades 22 extend into contact with theblade rub area 52 of the body 40. During the wear-in period, the tipsrub against the blade rub area 52, or at least a portion thereof. Afterthe wear-in period, the blade rub area 52 is exposed to high temperaturecombustion gases.

In use, the cooling fluid flowing through the cooling passage 60 entersthrough inlet hole 68 and travels through the portion 64 to the outlethole 62. The cooling fluid that exits the outlet hole 62 provides a filmof cooling fluid over the blade rub area 52 to help maintain the bladerub area 52 at a desired temperature. The routing of the cooling passage60 under and adjacent the coating 48 also helps to maintain the coatedportions 50 in the first area at a desirable temperature. Thus, thecooling passage 60 serves the dual purpose of helping to cool the coatedareas as well as film cooling the blade rub area 52. The disclosedcooling passage 60 may therefore reduce the need for other cooling tothe coated portions 50. For example, the coated portions 50 may becooled through the use of film cooling holes that are located on theleading edge 44 a (not shown).

With cycling of the engine between on and off conditions, or evenbetween throttle levels, different amounts of heat are generated. Therepeated heating and relative cooling of the blade rub area 52 causesthe body 40 at the blade rub area 52 to thermally expand and contract.The cooling passage 60 is provided to maintain the blade rub area 52 ata desired temperature to reduce the effects of thermal expansion andcontraction.

In comparison, a blade outer air seal member having a gas path side thatis entirely coated with a ceramic thermal barrier coating is subject towear against the tips of the blades during a wear-in period. The tipswear or spall away the ceramic coating in the blade rub area. Withcontinued use, the ceramic coating can spall and expose the underlyingbare metal to the high temperature combustion gases. With local exposureof the central portion of the BOAS, excessive temperatures and stressescan lead to early degradation of the segment. In areas outside of theblade rub area, less heat is generated. The difference in heatgeneration between the blade rub area and areas outside of the blade rubarea cause thermal stress in the axial direction of the blade outer airseal member. The thermal stresses can cause cracking in the coatingand/or in the underlying metal of the body. However, in the disclosedexample where sufficient cooling is provided to the blade rub area 52 toaccount for there not being any of the coating 48, the heat from thehigh temperature combustion gases can be adequately removed to limit theeffects of thermal expansion and contraction.

FIG. 4 illustrates another embodiment blade outer air seal member 232.In this example, the blade outer air seal member 232 is similar to theblade outer air seal member 32 shown in FIG. 2, in which the coating 48has a uniform thickness throughout. However, in this example, the bladeouter air seal member 232 includes a coating 248 that tapers axially. Asshown, the coating 248 is thicker at a first location 280 than at asecond location 282 that is closer to an axial center 284 of the bladeouter air seal member 232. For instance, the coating 248 is thickest atthe leading edge 44 a, the trailing edge 44 b, or both and reduces inthickness as a function of distance from the axial center 284.

In the illustrated example, the coating 248 on the first area (to theleft of the blade rub area 52 in the illustration) of the gas path side46 a tapers from the leading edge 44 a to a zero thickness at a terminaledge of the coating along the blade rub area 52. Likewise, the coating248 on the second area (to the right of the blade rub area 52 in theillustration) of the gas path side 46 a tapers in thickness from thetrailing edge 44 b toward a zero thickness at a terminal edge of thecoating 248 along the blade rub area 52. In a further example, thecoating 284 tapers only over a partial axial length of the first areaand/or the second area.

In operation, the tapered thickness of the coating 248 helps to reducethermal mechanical fatigue of the coating 248 due to heat cycling anddifference in temperature between the blade rub area 52 and the portionsoutside of the blade rub area 52 on which the coating 248 is disposed.That is, there is less of the coating 248 material near the blade rubarea 52, which is the hottest portion of the blade outer air seal member232.

FIG. 5 illustrates another example blade outer air seal member 332 in aperspective view and FIG. 6 illustrates the blade outer air seal member332 in cross-section. In this example, the blade outer air seal member332 includes a body 340 that extends between two circumferential sides342, axially between a leading edge 344 a and a trailing edge 344 b, andbetween a gas path side 346 a and a radially outer side 346 b oppositethe gas path side 346 a.

The blade outer air seal member 332 includes a coating 348 that isdisposed on a portion 350 of the gas path side 346 a. In this example,part of the coating 348 is disposed on a first area 350 a and anotherpart of the coating 348 is disposed on a second area 350 b. The areas350 a and 350 b are separated by the blade rub area 352 such that thecoating 348 is discontinuous on the gas path side 346 a.

The blade outer air seal member 332 includes a row 390 of cooling holesthat extend adjacent the coating 348 that is located on the leading edge344 a side of the blade outer air seal member 332. The cooling holes canextend under the coating 348, as shown in FIG. 3. As shown, the row 390is located closer to the coating 348 that is on the first area 350 athan to the coating 348 that is on the second area 350 b. Optionally,another row 392 of cooling holes may be provided along the coating 348that is on the second area 350 b. However, in some examples, the row 392is unnecessary because the cooling film emitted from the row 390 flowsover the surface of the coating 348 on the second area 350 b. Thecoating 348 on the first area 350 a is cooled by cooling holes 394 inthe leading edge 344 a.

In the illustrated example, the row 390 of cooling holes is adjacent aterminal edge 396 a of the coating 348 on the first area 350 a. Theother row 392 of cooling holes is adjacent a terminal edge 396 b of thecoating 348 on the second area 350 b. For instance, each hole in the row390 is an equivalent distance from the terminal edge 396 a and each holein the row 392 is an equivalent distance from the terminal edge 396 b.

The cooling holes in the blade rub area 352 help to maintain the bladerub area 352 at a desirable temperature. The areas 350 a and 350 boutside of the blade rub area 352 are thermally protected by the coating348 and therefore do not require as much cooling as the blade rub area352. In that regard, the areas 350 a and 350 b outside of the blade rubarea 352 do not include cooling holes. That is, some of the cooling thatmight otherwise have been used to cool the areas 350 a and 350 b outsideof the blade rub area 352 may instead be used to cool the blade rub area352 that does not include any coating thereon. Thus, the blade outerarea seal member 332 embodies a method of establishing a greater amountof cooling to the bare blade rub area 352 than to the areas 350 a and350 b that are coated by providing cooling holes on the blade rub area352 but not on the coated areas 350 a and 350 b.

Whereas coatings that are normally used on gas path side surfaces ofblade outer air seals must be abradable by having a certain porosity toallow the coating to wear away upon contact with the tips of the blades,the coatings disclosed herein do not contact the tips of the blades.There is therefore no need for the coatings to be abradable with acertain predetermined porosity. Thus, the porosity of the coatingsdisclosed herein may be reduced to substantially zero if desired,without regard to the abradability with the tips of the blades.Moreover, because the disclosed coatings are not in contact with thetips of the blades and see less heat, the composition of the coatingscan be varied from compositions previously used. However, in a fewexamples, the coating is or includes a ceramic material, such as yttriastabilized zirconia, gadolinia stabilized zirconia, or combinationsthereof.

Although a combination of features is shown in the illustrated examples,not all of them need to be combined to realize the benefits of variousembodiments of this disclosure. In other words, a system designedaccording to an embodiment of this disclosure will not necessarilyinclude all of the features shown in any one of the Figures or all ofthe portions schematically shown in the Figures. Moreover, selectedfeatures of one example embodiment may be combined with selectedfeatures of other example embodiments.

The preceding description is exemplary rather than limiting in nature.Variations and modifications to the disclosed examples may becomeapparent to those skilled in the art that do not necessarily depart fromthe essence of this disclosure. The scope of legal protection given tothis disclosure can only be determined by studying the following claims.

1. A blade outer air seal member comprising: a body that extends betweentwo circumferential sides, axially between a leading edge and a trailingedge, and between a gas path side and a radially outer side opposite thegas path side; and a ceramic coating initially disposed on a portion ofthe gas path side outside of a blade rub area of the gas path side suchthat the blade rub area is bare with regard to any of the ceramiccoating.
 2. The blade outer air seal member as recited in claim 1,wherein the coated portion includes a first area along the leading edgeand a second area along the trailing edge.
 3. The blade outer air sealmember as recited in claim 2, wherein the blade rub area separates thefirst area and the second area.
 4. The blade outer air seal member asrecited in claim 3, wherein the blade rub area includes acircumferential row of cooling holes that are located closer to thefirst area than to the second area.
 5. The blade outer air seal memberas recited in claim 1, wherein the blade rub area includes coolingholes.
 6. The blade outer air seal member as recited in claim 5, whereinthe coated portion is free of any cooling holes.
 7. The blade outer airseal member as recited in claim 1, wherein the coating thickness tapersaxially.
 8. The blade outer air seal member as recited in claim 7,wherein the ceramic coating is thicker at a first location than at asecond location that is closer to the axial center of the body.
 9. Theblade outer air seal member as recited in claim 1, wherein the blade rubarea includes a first circumferential row of cooling holes adjacent to afirst terminal edge of the coating and a second circumferential row ofcooling holes adjacent to a second, different terminal edge of theceramic coating.
 10. The blade outer air seal member as recited in claim1, wherein the ceramic coating has a uniform thickness throughout. 11.The blade outer air seal member as recited in claim 1, wherein the bodyincludes a cooling passage having an outlet hole that opens at the barearea and the cooling passage extends in the body in an axial directionsuch that the portion of the cooling passage is adjacent the ceramiccoating.
 12. A blade outer air seal member comprising: a body thatextends between two circumferential sides, axially between a leadingedge and a trailing edge, and between a gas path side and a radiallyouter side opposite the gas path side; a ceramic coating initiallydisposed on a portion of the gas path side such that an area of the gaspath side is bare with regard to any of the ceramic coating; and acooling passage having an outlet hole that opens at the bare area, thecooling passage extending in the body in an axial direction such that aportion of the cooling passage is adjacent the ceramic coating.
 13. Theblade outer air seal member as recited in claim 12, wherein the coatedportion includes a first area along the leading edge and a second areaalong the trailing edge.
 14. The blade outer air seal member as recitedin claim 13, wherein the blade rub area separates the first area and thesecond area.
 15. The blade outer air seal member as recited in claim 12,wherein the cooling passage extends from the outlet hole axially forwardin the body toward the leading edge.
 16. The blade outer air seal memberas recited in claim 12, wherein a portion of the cooling passage isaxially aligned with the coated portion.
 17. A method for enhancingdurability of a blade outer air seal member, the method comprising:providing a blade outer air seal member that includes a body thatextends between two circumferential sides, axially between a leadingedge and a trailing edge, and between a gas path side and a radiallyouter side opposite the gas path side, and a ceramic coating on aportion of the gas path side outside of a blade rub area of the gas pathside such that the blade rub area is bare with regard to any of theceramic coating; and establishing a greater amount of cooling to theblade rub area of the gas path side than to the portion that is coated.18. The method as recited in claim 17, including establishing a greateramount of cooling to the blade rub area of the gas path side than to theportion that is coated by providing cooling holes on the blade rub areabut not on the portions that are coated.